Festooning device and method for packaging a continuous length of material into a container

ABSTRACT

A festooning device is provided for packaging a continuous length of a material or product in a container at high operating speeds, with little or no operator adjustment until the container is completely filled. The festooning device can include an articulated paddle that further increases the fill of product from edge to edge in the container. The movements of the shuttle arm, container, and/or articulated paddle are synchronized to reduce the travel distance that the individual components of the festooning device, avoid overthrows of material over the upper edge of the container at high operating speeds, and provide maximum fill of the container. Also provided are a system and a method using the festooning device.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/770,762, filed on Feb. 28, 2013, and the benefit of U.S. Provisional Application No. 61/789,109, filed on Mar. 15, 2013, the contents of which are incorporated by reference in their entireties.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The present disclosure provides a festooning device and a method for using the festooning device for packaging a continuous length of a material or a product into a container. In particular, the present disclosure provides a festooning device that fills the container with fan folded, indexed layers at high operating speeds, resulting in a container that has more of the product, and is more stable than those filled by conventional dispensing devices.

2. Description of Related Art

Conventional devices that dispense a continuous web of material or a product into a container have several disadvantages that limit its practicality. Conventional devices that operate by moving a dispensing arm back-and-forth to form vertical fan folded layers into individual stacks or “lanes” that are cut and spliced together to fill the container.

Conventional devices use a single movement, namely, moving the dispensing shuttle back-and-forth over the top of the open container, to form several adjacent “lanes” of the product inside the container. However, a single back-and-forth dispensing movement produces lanes of the product that do not completely reach from edge to edge near the bottom of the container, and then “overthrows” the product over the outer edge of the container as the material nears the top of the container for each lane. This results in containers that are incompletely filled or require frequent operator adjustments during filling. These effects are exacerbated when the product is too soft, or too stiff, and generally require the dispensing speed to be considerably slowed. But even at low operating speeds, a single dispensing movement by the dispensing shuttle generally cannot completely fill the interior space of the container or provide a level, stable fill of product therein.

SUMMARY OF THE DISCLOSURE

The present disclosure provides a festooning device for packaging a continuous web of a material or a product into a container at high operating speeds.

The festooning device can include an articulated paddle that pushes the material farther toward and into each edge of the container to achieve a complete fill, and prevents “overthrows” of the material as the level of the material nears the top of the container.

The festooning device of the present disclosure may further include a sensor that detects the level of the material in the container, which can be used to adjust the travel distance of the dispensing shuttle and/or the oscillation of the articulated knuckle, so that the product reaches the container edges and continues to be level for maximal fill, and avoids “overthrowing” the web of material as the fill level approaches the top of the container.

The festooning device of the present disclosure can dispense a material or a product of varied thickness and/or stiffness into a container without operator adjustments, even at high operating speeds.

The festooning device of the present disclosure can synchronize the movements of the dispensing shuttle, the container, and/or the articulated paddles to provide optimal filling even at high operating speeds. Two synchronized movements reduce the travel distance of the individual moving components and provide more-complete, more-level filling of the product in the container at high operating speeds. Three synchronized movements provide still further reductions in the movements of the individual moving components and even more optimal filling of the container. In addition to saving production time, reducing the travel distances of the individual parts increases the longevity and reduces the need to re-index the festooning device and the conveyor on which the container moves.

The festooning device of the present disclosure dispenses the material or product into the container in “indexed” rows that form successive horizontal layers until the container is completely filled. The indexed rows and successive horizontal layers create a natural separation plane between adjacent rows and layers of the material, permitting the end-user to dispense the material quickly and cleanly.

The festooning device of the present disclosure fills the entire container with a single, unbroken, continuous web of a material or product without cuts or splices between adjacent lanes or stacks, as in conventional dispensing devices. The indexed rows and horizontal layers of material make the filled container more stable, and safer to handle, and eliminate the need to separate individual stacks with physical dividers to prevent the stacks from tipping when the end user removes the material from the container.

The present disclosure further provides a method of packaging a single, continuous web of a product, such as an absorbent food pad, from a large-diameter source roll into a rectangular container by fan folding, using a festooning method that forms indexed rows of the product in the container at commercial production speeds.

Still further, the present disclosure provides a method that employs a production line that includes a pivoting “dancer assembly” to permit packaging continuous webs of different thicknesses, without having to adjust production line settings. A sensor on the dancer assembly can be used to automatically regulate the speed of the motor driving the source (feeder) roll to prevent “snatching” and “snapping” of the continuous web, which improves web control and eliminates web breaks.

The present disclosure yet further provides that the subject container can have an adjustable deflector positioned along the upper edges that reduce or eliminate overhangs of the product over the top edge of the container when fan folding at commercial production speeds.

The present disclosure provides a method of packaging a continuous web in a container to form indexed rows or layers of the continuous web in the container, where each row or layer of the continuous web that is dispensed into the container is slightly offset or shifted (i.e., indexed) in relation to the previous row or layer, to partially overlap the previous layer. As additional rows of a product or material continue to be dispensed into the container, the indexed rows form horizontal layers that completely fill the container.

The method further provides festooning the fan folded rows of material in indexed layers to provide increased stability and safety while the container is being filled, and when dispensed by the end-user. The indexed rows and successive horizontal layers formed by the festooning method of the present disclosure create a natural separation plane between adjacent rows of the product, permitting the end-user to dispense the product quickly and cleanly. The present method also eliminates the need to separate individual stacks of fan folded products with physical dividers (that prevent the rows from shifting or falling down inside the container after some portion of the product is removed by an end-user) and splices between adjacent rows.

Still further, the present method permits a very large amount of the continuous web to be packaged in the container, with little “crowning” (or other wasted space) in the container. A rectangular container filled with a fan-folded continuous web of product by the present festooning method permits the end-user to dispense the entire contents of the container with a single set-up, reducing down time and inconvenience.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an exemplary embodiment of a festooning device of the present disclosure.

FIG. 2 is a right side view of the festooning device of FIG. 1.

FIG. 3 is a top view of the festooning device of FIG. 1.

FIG. 4 is a front view of the frame assembly portion of the festooning device of FIG. 1.

FIG. 5 is a right side view of the frame assembly portion of the festooning device of FIG. 1, and of one of the foot pads.

FIG. 6 is a top view of the frame assembly portion of the festooning device of FIG. 1.

FIG. 7 is a detail view of the drive motor mount, nipped roll drive, articulating arm fixed pivot support, and idler roll support components of the festooning device of FIG. 1.

FIG. 8A, FIG. 8B and FIG. 8C are detail views of further components of the portion of the festooning device shown in FIG. 7.

FIG. 9A and FIG. 9B are detail views of the tending side idler roll support for the frame assembly shown in FIG. 7.

FIG. 10 is a detail view of an idler roll in the frame assembly portion of the festooning device of FIG. 1.

FIG. 11 is a front detail view of the drive motor mount, nipped roll drive, articulating arm fixed pivot support, and idler roll support components of the frame assembly portion of the festooning device of FIG. 1.

FIG. 12 is a right side view of the frame assembly further illustrating the tending side idler roll support components of FIG. 9A and FIG. 9B, and the idler roll component of FIG. 10.

FIG. 13 is a top side view of the frame assembly further illustrating the tending side idler roll support components of FIG. 9A and FIG. 9B, and the idler roll component of FIG. 10.

FIG. 14 is detail view of the articulating nipped roll drive assembly component of the festooning unit of FIG. 1.

FIG. 15 is another detail view of the articulating nipped roll drive assembly component of the festooning unit of FIG. 1.

FIG. 16 is yet another detail view of the articulating nipped roll drive assembly component of the festooning unit of FIG. 1.

FIG. 17 is still another detail view of the articulating nipped roll drive assembly component of the festooning unit of FIG. 1.

FIG. 18A through FIG. 18C are detail views of the articulating nipped roil drive component of the festooning device of FIG. 1. FIG. 18A is a detail view of the articulating nipped roll drive showing the drive shaft from the gearbox. FIG. 18B is a detail view of the articulating nipped roll drive showing the knuckle shaft. FIG. 18C is a detail view of the articulating nipped roll drive showing the drive shaft to nipped roll.

FIG. 19 is a detail view of the shuttle plate component of the festooning device of FIG. 1.

FIG. 20 is another detail view of the shuttle plate component of the festooning device of FIG. 1.

FIG. 21 is a detail view of the shuttle plate of FIG. 19.

FIG. 22 is another detail view of the shuttle plate of FIG. 19.

FIG. 23A is a front view of a nipped roll idler of the festooning device of FIG. 1. FIG. 23B is a right side view of the nipped roll idler of FIG. 23A.

FIG. 24 is a front view of the shaft used for the nipped roll idler of FIG. 23A.

FIG. 25A is a front view of the slide mount for the nipped roll idler of FIG. 23A. FIG. 25B is a right side view of the slide mount of FIG. 25A.

FIG. 26A is a front view of the driven nipped roll with shaft of the festooning device of FIG. 1. FIG. 26B is a right side view of the driven nipped roll and shaft of FIG. 26A.

FIG. 27 is a front view of the rod end attachment of the festooning device of FIG. 1.

FIG. 28A is a front view of the mounting spacer of the festooning device of FIG. 1. FIG. 28B is a right side view of the mounting spacer of FIG. 28A.

FIG. 29 is front view of an exemplary embodiment of the festooning device of FIG. 1 having an articulating paddle, and indicating its attachment on the actuating arm, and pivot point. The movement of the articulating paddle is marked as a center (neutral) position, “extreme south position” and “extreme north position.” For clarity, the festooning device of FIG. 1 is shown without much of its support structure and assembly components.

FIG. 30 illustrates the range of movement of the articulating paddle of FIG. 29 at its attachment point on the actuating arm and at its tip.

FIG. 31 is a top view of the articulating paddle(s) of FIG. 29, and their position relative to the drive belts of the festooning device of FIG. 1.

FIG. 32 is a right side view of another embodiment of the articulating paddles of FIG. 29 that are slotted for weight reduction.

FIG. 33 illustrates the range of movement (travel) of each of the articulating paddles of FIG. 29 at its attachment point on the actuating arm and at its tip (in relation to the shuttle travel) at its center position, “extreme north position,” and “extreme south position.”

FIG. 34 illustrates another embodiment of the festooning device of FIG. 1 having articulating paddles that pivot using a cam follower in a cam track, and indicating the range of movement of the articulating paddles (in relation to the shuttle) from “extreme south position” to “extreme north position.”

FIG. 35 is a schematic of an exemplary embodiment of a portion of a production line to package a continuous web of absorbent pads into a container according to the present disclosure.

FIG. 36A illustrates a cross-section of the side of a large container to clearly show the dispensing of layers of the absorbent web into a container by the method of the present disclosure.

FIG. 36B illustrates the problem of overhang, when a portion of the continuous web is thrown over the upper edge of the container at high operating speeds.

FIG. 36C illustrates the use of a pair of “deflector plates” along the upper edges of the container to prevent the overhang of the continuous web shown in FIG. 36B.

FIG. 37A is a perspective view of an exemplary embodiment of the present disclosure illustrating a rectangular container being filled with a continuous web in an exemplary embodiment of the present method.

FIG. 37B is a magnified section of a portion of the continuous web being placed in the rectangular container in FIG. 37A. A second row of the continuous web that is indexed a certain distance in relation to a first row of the product is also shown.

FIG. 38A, FIG. 38B, and FIG. 38C illustrate a sequence of steps for placing indexed rows of a product or material in a container by the method of the present disclosure.

FIG. 38A illustrates the first step, in which a first row of a product or material is laid on the bottom of a container.

FIG. 38B illustrates the next step, in which a second row of the same material is laid in the container in an opposite direction from the first row, and which is indexed a certain distance in relation to the first row, so that the first row and second row partly, but do not completely, overlap.

FIG. 38C illustrates the next step, in which a third row of the same product or material is laid in the container in an opposite direction of the second row. The third row is indexed in relation to the second row. The process would continue (not shown) until a single horizontal layer of a fan folded product is formed.

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring to the drawings, and in particular, FIGS. 1 through 3, there is provided an exemplary embodiment of a festooning device of the present disclosure for packaging a continuous web of a material or a product in indexed rows to form horizontal layers in a container (container not shown).

FIG. 4 through FIG. 28B provide detail views of specific components of the festooning device of FIG. 1, and are described more fully below.

FIG. 29 through FIG. 34 illustrate an embodiment of the festooning device of FIG. 1 having an articulating paddle (also called an articulating knuckle herein) that improves the performance of the festooning device and fill of the container, as described more fully below.

FIG. 1 shows an exemplary embodiment of a festooning device of the present disclosure. The festooning device includes a frame assembly (detailed in FIG. 4 through FIG. 6) having gussets and foot pads, a drive motor and a drive motor mount, a nipped roll drive, an articulating arm fixed pivot support, and an idler roll support (detailed in FIG. 8A, FIG. 8B, FIG. 8C, FIG. 11 and FIG. 12). The frame assembly portion of the festooning device further includes a tending side idler roll support (detailed in FIG. 9A, FIG. 9B, FIG. 11, FIG. 12 and FIG. 13) and one or more idler rolls (detailed in FIG. 10, FIG. 12 and FIG. 13). The festooning device further includes an articulating nipped roll drive assembly (detailed in FIG. 14, FIG. 15, FIG. 16, FIG. 17, FIG. 18A, FIG. 18B, and FIG. 18C). The festooning device still further includes a shuttle plate assembly (detailed in FIG. 19, FIG. 20, FIG. 21, and FIG. 22). The festooning device further includes a nipped roll idler (detailed in FIGS. 23A and 23B), nipped roll idler shaft (detailed in FIG. 24), and a nipped roll idler slide mount (detailed in FIG. 25A and FIG. 25B). The festooning device can include a driven nipped roll and shaft (detailed in FIG. 26A and FIG. 26B), a rod end attachment (detailed in FIG. 27), and a mounting spacer (detailed in FIGS. 28A and 28B).

The festooning device of the present disclosure includes a linear actuator. In the embodiment shown in FIGS. 1 through 3, the linear actuator may be fully-enclosed. The movement of the linear actuator and the articulating nipped roll drive assembly at its starting position, and at four other positions, are shown in FIG. 1.

As shown in FIG. 29, the festooning device may further include an articulating paddle, also called an articulating knuckle herein. The articulating paddle preferably is a matched pair of paddles that are opposite each other and slightly oriented toward each other to come together at a tip at one end. An exemplary embodiment of the articulating paddles and their movements are illustrated in FIG. 30, FIG. 31, FIG. 32, and FIG. 33. The articulating paddle is attached to an actuating arm. The articulating paddles each have a pivot point (shown in FIG. 29 and FIG. 30). Generally, the articulating paddles move in a swinging motion from a center (neutral) position to oscillate between an “extreme south position” and an “extreme north position,” as shown in FIG. 29, FIG. 30, and FIG. 33.

The articulated paddle moves back-and-forth as the shuttle moves back and forth. This movement of the articulated paddle helps to push the continuous web of the material or product into the edge of the container. This provides a better fill, and a level fill of the container, as compared with conventional techniques.

The movement (swing) of the articulated paddle is programmable. The movement (i.e., the swing or “whip”) of the articulated paddles may be controlled by a programmable controller and a motor-driven servo.

Alternatively, the movement of the articulated paddles can be controlled by the addition of weights at (or near) the bottom of the articulated paddles, so that the amount of movement of the articulated paddles is partially momentum-driven. Depending on the amount of movement (whip) generated by the travel of the dispensing shuttle, the movement of the articulated paddles can be adjusted by using different amounts of weights, and/or moving the weights nearer or farther from the paddle tips. The weights may be added manually by the operator. In this way, movement of the articulated paddles can be controlled without motors or electronic controllers.

One or more sensor positioned on the framework and/or on the shuttle, measures the fill level of the material inside the container. This sensor can be, but is not limited to, an ultrasonic sensor. In a preferred embodiment, the sensor is an ultrasonic sensor that is fixed to the framework.

The distance that the shuttle travels (i.e., how close the thread of material comes to the edge of the container) has a significant effect on the neatness of the product as it is dispensed into the container, and the distance is not a constant. For example, when the box is nearly empty, the stroke distance must be greater to lay down the product neatly in the container. The stroke distance should decrease as the fill level of the product increases in the container. By the time the fill level is nearly to the top of the container, the stroke distance must be considerably shorter than when filling began, so that the material is not “thrown” out over the top edge of the container by the shuttle motion at high operating speeds.

The measurements of the fill level in the container detected by the one or more sensors will automatically adjust the travel of the shuttle based on that level. As noted above, as the sensor measures that the fill level in the container is rising, the signal will be sent to a controller that decreases the travel of the shuttle in relation to that fill level. In an exemplary embodiment, the electronic power required to achieve this can come from a touch screen controller on the festooning device. These controllers can have a user-friendly display that improves the operator-machine interface, and also provide a capability to store programmable data that are specific to different materials or products that can be dispensed into the container by the festooning device.

For example, when the shuttle moves 18″ from its center position to its extreme north position, the associated 18″ of belt travel causes the 36T sprocket to rotate 1.588 revolutions. The 32T sprocket also rotates 1.588 revolutions, which causes its belt travel (and the movement of the actuating arm) to be 16″. Movement of the end of the actuating arm by 16″ while the pivot point is also moving 18″ (i.e., 2″ relative movement) results in 24″ of movement at the tip of the articulating paddle, as shown in FIG. 30. These same relative motions of the carriage to the tip of the articulating paddle exist for the entire range of motion of the components as they cycle from the extreme north to extreme south.

For reference in the calculations above, a 36T sprocket pitch diameter is 3.609″. 36T sprocket pitch circumference is 3.609×3.14159, which equals 11.338″. 18″ of belt travel results in 18″/11.338″ per revolution, which equals 1.588 revolutions. 32T sprocket pitch diameter is 3.208″. A 32T sprocket pitch circumference therefore is 3.208×3.14159, which equals 10.078″. The belt travel for a belt on a 32T sprocket is 1.588 revolutions×10.078″ per revolution, which equals 16″.

In an alternative embodiment, an articulating chute between nipped rolls and the deposit point in the container may be used. This would permit control of the continuous web of material and position that material precisely near the edge of the container without allowing the material to free-fall more than a few inches, so that the new row or layer can nestle on the product layer immediately below.

The nipped roll speed and resultant web speed can be held constant during the filling operation. As the container fills, the speed of the carriage needs to change as the drop distance of the continuous web of material decreases. For instance, if the carriage speed does not increase as the container fills, too much of the product is deposited at the edge of the container before the carriage changes direction. This can be avoided by programming the controller to adjust carriage speed.

FIG. 32 shows that the articulated paddles can be slotted for weight reduction.

As shown in FIG. 29 through FIG. 33, the articulating paddles are straight members. This accomplishes having the continuous web of material reach each of the opposite sides of a large container, such as a large box that is 48″ wide. The straight member is shown as unjointed, which completely avoids any hang-up point for the continuous web that might hamper free flow. However, in an alternative embodiment, the articulating paddles can have one or more joints, like an elbow.

FIG. 34 illustrates another embodiment of the festooning device having articulating paddles, as an alternative to the “belt” versions in FIG. 29 through FIG. 33. In FIG. 34, a cam follower in a cam track is used to pivot the articulating paddle. The shuttle and nipped rolls move 36″ from one end of travel to the other, and the tip of the articulating paddle moves 48″ from one end of travel (“extreme south position”) to the other (“extreme north position”).

The “belt” embodiment in FIG. 29 through FIG. 33 offers advantages of less severe mechanical action at high operating speeds, potentially less equipment wear, and possibly less jam risk than associated with other options, including those using a cam.

The festooning device of the present disclosure can be used in a variety of systems for packaging a continuous web (or thread) of a product or material into a container. As a non-limiting example, the festooning device in this disclosure can be used with the methods and components described below.

The festooning device of the present disclosure provides for a more complete fill of a continuous web of a material or product in the container as compared with conventional techniques. As an example, a 48″×48″ box can be filled with a continuous web of about 42,000 absorbent food pads having individual dimensions of about 4″×7″.

The festooning device of the present disclosure also permits dispensing a continuous web of a material or product in a container at much faster operating speeds as compared with conventional techniques. For example, the present festooning device permits operating speeds of about 280 feet per minute to about 400 feet per minute, as compared with conventional techniques that can accurately operate at speeds of about 150 feet per minute.

The festooning device of the present disclosure can be used as part of a production system where synchronized movements of two or three components are used to fill container more precisely to the edges, with a larger total amount of the product and at much higher operating speeds described above. The separate movements of the shuttle arm, the articulating paddle, and/or the container (or any two of these movements) can be synchronized for faster, level, and complete filling of the container. For example, in one embodiment, if the movement of the shuttle arm is “North-South,” the synchronized movement of the container is “East-West.” A further (swinging) movement of the articulated paddles, which is synchronized to one or both of the shuttle arm movement and the container movement, permits still finer adjustments to the fill at the high operating speeds described above. Stated another way, if the movement of the shuttle arm is considered to be on an X-axis, the movement of the container is on a Y-axis. The fill depth of the container is measured by a sensor on a Z-axis. Measurement of fill depth on the Z-axis by the sensor affects the movement(s) of the shuttle arm, articulating paddles, and the container on the X-axis and Y-axis.

Another advantage of synchronizing any two movements of the shuttle arm, articulating paddles, and the container, is minimizing the movement(s) of each of these components, and still achieve better fill of the container at higher production speeds than conventional techniques. Synchronizing all three movements (shuttle arm, articulating paddles, and container) provides still further minimizing the movements of each component, and optimizing the fill at high production speeds.

By contrast, conventional filling methods employ only one (1) movement at a time to dispense the product into a container, namely, moving the shuttle arm back-and forth over the top of the container until an entire vertical stack (lane) of the product reaches the top, after which the material is cut and spliced, and the shuttle arm is indexed by one width of the product to start a new stack in the container. Depending on the thickness and/or stiffness of the product, as well as the amount of hysteresis in the “throw” of the material, the operator for conventional techniques must make frequent adjustments to the filling of the container. This is in contrast to the festooning device of the present disclosure, for which the operator is not required to make any adjustments until the entire container is filled with a single, continuous web of the material or product, and completely eliminates the need to cut and splice as a container is filled.

The festooning device of the present disclosure has improved reliability, longevity of the equipment, and still more increase in speed of operation as compared with conventional equipment and techniques for dispensing a continuous web of products into a container. Current festooning devices reciprocate a shuttle plate that carries nipped rolls to pull the web through the device, a drive motor and gearbox to drive the nipped rolled, and air cylinders to open and close the nipped rolls. Air lines to the cylinders and electrical cables to the motor are suspended overhead and flex back and forth with each round trip completed by the shuttle. Air lines and electrical cable are subject to damage due to the constant flexing. All of the equipment mounted on the shuttle plate adds up to about 75 pounds of additional weight to move back and forth.

As shown in FIGS. 1 to 3, the exemplary embodiment of the festooning device disclosed herein removes everything from the shuttle plate except the nipped rolls and two small mechanical clamps in place of the air cylinders to open and close the nipped rolls. This is a reduction in weight of about 65 pounds. The drive motor is mounted above the shuttle in a fixed location and the drive to the nipped rolls will be accomplished by a drive belt and an articulating arm that follows the shuttle motion. The shuttle is mounted on two self-contained linear actuating units whose speed and acceleration capabilities exceed what is actually needed. These mechanical changes provide improvements of reliability, speed, and efficiency of the present festooning device as compared with conventional devices.

In alternative embodiments, the festooning device further includes electronic controls that improve changeover time between production runs, automatically stop the festooning machine when the target material length or product count in the container is obtained, and/or automatically monitor and adjust the travel distance of the shuttle and nipped rolls depending on the fill level of the container. Such controls also help minimize the required movements of the shuttle arm, articulated paddles, and container to achieve the desired fill at high production speeds.

The dispensing shuttle may move north-south and/or east-west to dispense fan-folded rows of the continuous web in the container. The servo drives and servo motors replace AC drive motors to provide motive force to the traversing mechanisms. The servo drives and servo motors improve reaction time and precise starting, stopping, reversal and positioning of traversing mechanisms.

Movement of the festooning device and/or the container while the continuous web is being dispensed therein can improve the speed and efficiency of the present method. The container can be positioned on a mechanical device that can tilt, rock, or move the container in any direction during filling. Tilting the container as the continuous web approaches each edge of the container also assists the fan folding close to each edge, thereby maximizing the use of space inside the container. Similarly, after the container has been shipped to an end-user, tilting and/or moving the container can increase the speed and efficiency by which the continuous web is dispensed from the container.

The container of the present disclosure can be a large box, or any container that is able to hold a large quantity of a product or material. The container can be made of any material, including, but not limited to, cardboard, wood, metal, paper, plastic, composite, or polymer. The container preferably has dimensions of about forty inches (40″) by about forty-eight inches (48″) by about forty-six inches (46″), in order to fit easily on a pallet. However, the container can be of any dimension that permits indexed rows or layers of a continuous web of material or product to be packaged therein.

As used herein, an “end-user” is a customer or employee who removes and uses the continuous web of a material or product that has been previously packaged in a container for its intended use.

The present festooning device can be used for packaging and dispensing a continuous web of a variety of products or materials, including those that are fibrous materials, such as fabrics and non-wovens. The present method for packaging can also be used for packaging and/or dispensing finished products, including products that can be dispensed as a continuous piece and cut by the end-user, for example, absorbent food pads and/or other absorbent articles. The product or materials that are packaged by the present method are typically uniform in thickness, size, and/or texture. However, the present method can also be used for packaging a continuous length of a product having varied parameters at various locations along in its continuous length, as long as the successive rows could be laid into the container.

As an example, a continuous length of absorbent food pads of more than 21,000 linear feet can be packaged in the container by the present festooning device as a single, continuous length, with marks or perforations to indicate the individual food pads. To remove the absorbent food pads from the container, an end-user is able to set up the packaged container one time to permit all of the absorbent food pads to be removed continuously and quickly. The absorbent food pads, in this example, can be cut (or separated along pre-made perforations) to a desired size to fit in a food tray as they are dispensed.

The festooning device of the present disclosure also offers several other advantages over conventional packaging techniques that places long strips of products or material in a container. Conventional packaging techniques lay successive rows of product or material to form a series of stacks or “lanes” in the container, which can cause the container to become unstable during the dispensing process as the stacks are depleted, and risks having the remaining stacks fall over into the interior of the container that is vacated during the dispensing process. By comparison, the horizontal layers laid in by the present festooning device can be dispensed by an end-user without causing instability of the container, as the continuous web of the material or product is dispensed evenly from the length and width of the entire container.

The present festooning device can also be used to avoid the need to place dividers between the vertical stacks or lanes that are formed by conventional packaging techniques. The horizontal layers that are laid in by the present festooning device offer greater stability when removing the product from the container, eliminate the use of dividers, and maximize the use of space within the container, thereby providing the end-user with greater safety and speed.

Referring to FIG. 35 and FIGS. 36A through 36C, there is provided an exemplary embodiment of a production line, or system, generally represented by reference number 10, for packaging a continuous web 20 of absorbent pads 22 by festooning into a container 60 according to the method of the present disclosure.

As shown in FIG. 35, a feeder roll 12 supplies a continuous web 20 that is packaged in a large rectangular container. Feeder roll 12 has an inner tube 14 to form that is mounted onto spindle 16. A drive motor 32 drives (spins) feeder roll 12 so that continuous web 20 unwinds and is dispensed from the top side of feeder roll 12 at commercial production speeds.

Continuous web 20 passes around one or more pulleys in production line 10. In the exemplary embodiment in FIG. 35, production line 10 has four pulleys 52, 54, 56, 58 that help guide and control continuous web 20 in the production line.

After being dispensed from feeder roll 12 and, optionally, one or more pulley 52, continuous web 20 passes around a “dancer assembly” 35. Dancer assembly 35 includes a fixed arm 41 (also called fixed rod) that is connected to two rollers at opposite ends; namely, a first dancer pulley 36 at one end of fixed arm 41, and a second dancer pulley 38 at its other end. Fixed arm 41 of dancer assembly 35 has a pivot point 40 about which the fixed arm pivots, or rotates. Consequently, when the top roller (first dancer pulley 36) goes to the right, then the bottom roller (second dancer pulley 38) must go left. Mechanical tension of continuous web 20 causes dancer assembly 35 to oscillate back-and-forth. In a preferred embodiment, such mechanical tension generates the oscillation of fixed arm 41 of dancer assembly 35. However, in another exemplary embodiment, a combination of mechanical tension and electrical control may be used to regulate oscillation of dancer assembly 35.

Fixed arm 41 of dancer assembly can freely rotate until it reaches a mechanical stop (not shown) that permits about 45° of rotation from neutral. The mechanical stop may be integral to a framework (not shown) that supports part of production line 10. In another embodiment, the mechanical stop is part of the dancer assembly itself. The mechanical stop prevents fixed arm 41 from rotating 360°. In a preferred embodiment, fixed arm 41 is able to oscillate (to rotate or pivot about pivot point 40) about 20° in either direction (±20°) from a neutral position.

Dancer assembly 35 has a dancer belt pulley 42 at pivot point 40 that is about half-way between first dancer pulley 36 and second dancer pulley 38. Dancer belt pulley 42 is connected by a dancer belt 46 to a second dancer belt pulley 44, which is set a small distance away from the first belt pulley.

The position of dancer assembly 35 is detected by one or more dancer position sensor 48. In a preferred embodiment, dancer position sensor 48 is a single-turn potentiometer. As dancer belt 46 turns and continuous web 20 passes around the dancer assembly, dancer position sensor 48 measures the position of dancer assembly 35 from its “low point” to its “high point,” and generates a signal 49 that goes to motor 32 to adjust speed. Dancer position sensor 48 is typically positioned outside of the framework of the production line.

Motor 32 is also connected to PLC (Programmable Logic Controller) 34. PLC Controller 34 measures speed differentials between incoming and outgoing speeds, and generates a signal 39 that is sent to motor 32. PLC Controller 34 generates a master speed reference based on a dial setting that the operator controls to either accelerate or decelerate the speed of motor 32 a certain amount. The speed of motor 32 (and thus the speed by which continuous web 20 is dispensed from feeder roll 12) is initially set by the operator based on the size, thickness, and other physical characteristics of the particular feeder roll 12 that is loaded on spindle 16. After the motor is running, its speed may be altered based on signal 49 received from dancer position sensor 48 and/or reference signal 39 received from PLC controller 34, as required to maintain a constant feed and tension control based on how fast the production line calls for additional material. If feeder rolls of the same size are used consistently, the production line operator may not need to adjust the initial settings for motor 32. However, the operator may have to adjust the speed input data for motor 32 if the size of the feeder roll is either smaller or larger than the feeder roll for which the speed input data was previously set. For example, if the production is set up for a feeder roll that is a 50″ roll, and the next production run requires a 25″ feeder roll (or, conversely, requires a 55″ feeder roll), the operator may have to input different speed data to motor 32. Generally, the operator needs only to input such data at motor 32, rather than re-setting any data in PLC Controller 34.

An example of motor 32 includes, but is not limited to, an ABB motor drive. The ABB motor drive can be programmed to receive input data from the operator, as well as signals 39 and 49 from PLC Controller 34 and dancer position sensor 48, respectively.

For example, if the feed of continuous web 20 to dancer assembly 35 is too slow for the production line, the dancer assembly will rotate in a counterclockwise direction. Dancer position sensor 48 and PLC controller 34 will generate and signals 49 and 39, respectively, that are received by the driver software in motor 32. These signals will cause motor 32 to increase speed and thereby increase the speed of unwinding of continuous web 20 to meet the increased demand for material (continuous web 20) in the production line.

Dancer assembly 35 allows the present method to automatically adjust for continuous webs that vary in thickness, without requiring operator adjustment of the settings for motor 32 or other parts of production line 10. If the production line always used the same thickness of continuous web 20 every time it was used, there would be no need for a dancer assembly, once the initial settings were fine-tuned by the operator. Without the dancer assembly device, motor 32 is sensitive enough to variations in the thickness of the continuous web to detect a difference of thickness of as little as 0.025 inches, and thereby require operator adjustment. However, the dancer assembly device of the present method allows production line 10 to use continuous webs 20 that can vary in thickness by as much as about 0.125″ (⅛^(th) of an inch), without requiring an operator to adjust any production line settings. This flexibility of the present method is due to the ability of the dancer assembly device to pivot about ±20°.

For example, the dancer assembly of the present method enables the method to accommodate, without requiring the system to be adjusted by the operator, a continuous web of absorbent food pads that are 4-ply of tissue with polyethylene film on either side (thin), which is approximately 1/32^(nd) of an inch, to those absorbent food pads that are 18-ply of tissue with polyethylene film on either side (thick) that are approximately ⅛^(th) of an inch. The present method could accommodate absorbent food pads that are 3/16^(th) of an inch and ¼″, up to those thick absorbent food pads having 30-ply of tissue between polyethylene outer layers, without requiring adjustment by the operator.

After passing around dancer assembly 35, continuous web 20 then continues on production line 10 to pass over or under one or more pulleys 54, 56, 58, which guide and control the material. As shown in FIG. 35, continuous web 20 then exits production line 10 at about exit point 59.

After leaving production line 10 at exit point 59, continuous web 20 proceeds to the festooning unit shown in FIGS. 36A to 36C. In FIG. 36A, container 60 is illustrated in cross-section to more clearly show that it is partially filled with continuous web 20 by festooning device 80 by the present method. In each of the embodiments shown in FIG. 36A to 36C, festooning device 80 is a pair of rubber-nipped rolls that pull continuous web 20 to dispense a continuous web of material or product (for example, absorbent food pads) into the rectangular container. Another example of a festooning device 80 includes, but is not limited to, a gantry. Nipped rolls 80 can be mounted on a traversing mechanism and move back-and-forth above the container, traveling from one edge of the container to the other to form the fan-folded rows of continuous web 20 that will fill the container.

Festooning device 80 may move north-south and/or east-west to dispense fan-folded rows of continuous web 20 in container 60. Servo drives and servo motors replace AC drive motors to provide motive force to the traversing mechanisms. The servo drives and servo motors improve reaction time and precise starting, stopping, reversal and positioning of traversing mechanisms.

Movement of the festooning device and/or the container while the continuous web is being dispensed therein can improve the speed and efficiency of the present method. The container can be positioned on a mechanical device that can tilt, rock, or move the container in any direction during filling. Tilting the container as the continuous web approaches each edge of the container also assists the fan folding close to each edge, thereby maximizing the use of space inside the container. Similarly, after the container has been shipped to an end-user, tilting and/or moving the container can increase the speed and efficiency by which the continuous web is dispensed from the container.

Festooning device 80 may be lighter (or at least is a consistent weight) and more maneuverable than container 60, which can vary considerably in weight as the container fills. However, placing container 60 on a mechanical device, such as one or more cams, that permits container 60 to be easily tilted, rocked, and moved in any direction, can also be employed, so that the continuous web fills the maximum amount of available space inside the container. The movement of container 60 can also create an offset among successive rows of the continuous web for efficient layering for packaging, as well as creating a natural separation plane between layers when the continuous web is dispensed for use.

For example, festooning device 80 can move straight back and forth, while container 60 shifts a certain distance between adjacent rows of continuous web 20. Combining the movements of festooning device 80 and container 60 can be an aid to efficient dispensing of products or materials into container 60 by the present method. The movements can achieve different ends: i.e., container 60 can be tilted at the end of placing each row into the container, to help the rows fall all the way toward the edges to provide maximum filling of space inside container 60, while festooning device 80 is moved a certain distance to create a slight offset between successive rows of the continuous web.

Container 60 can be tilted from a neutral level position by movement of the cams so that the upper edge of container 60 is between about 1 to about 70 degrees above or below neutral position, and preferably between about 5 to about 45 degrees from neutral position. After a row of the continuous web 20 is placed in container 60, and festooning device 80 reverses direction and begins to place the next row in the opposite direction in relation to the previous row, container 60 returns to a neutral position, and then is tilted toward the opposite side just as the new row approaches the opposite edge of container 60, helping to extend the new row closer to the edge of container 60.

Later, when continuous web 20 is being removed from container 60 by an end-user, container 60 can again be advantageously placed on a moveable device, including one or more cams that permit container 60 to be moved and/or rocked back and forth to assist removing the continuous web 20 from container 60.

FIG. 36B illustrates a potential problem with filling container 60 at the high operating speeds required for commercial production. At high operating speeds, a strip of continuous web 20 can be “thrown” too far by festooning device 80 so that a small portion of continuous web 20 flies over the outer edge of container 60 to form an overhang portion 29 shown in FIG. 36B.

However, the problem of forming an overhang portion 29 can be avoided by placing deflector plates 74, 76 at the upper edges of container 60, as shown in FIG. 36C.

Deflector plates 74, 76 stop the horizontal travel of continuous web 20 and directing the web to slide downward along one of the inside walls of container 60. The deflector also provides more consistent filling of the container, and minimizes empty space at the edges of the container walls. Although the embodiment shown in FIG. 36C illustrates two deflector plates, there may be one, two, three, four, or more deflector plates that are positioned around the upper edge of container 60. Deflector plates 74, 76 can be made of a rigid or flexible material, depending on the size and weight of continuous web 20, operating speed of the festooning device, and the nature of container 60. In an exemplary embodiment, deflectors 74, 76 are each made of metal. In a preferred embodiment, deflector plates 74, 76 are made of polished metal that reduces or eliminates friction as continuous web 20 strikes it at the end of each pass. Deflector plates 74, 76 can be adjustable in any direction. In a preferred embodiment, deflector plates 74, 76 are adjustable in the vertical direction.

Container 60 has four vertical sides (two of these sides 62, 64 are shown in FIGS. 36A to 36C), a bottom 70, and a top 72. Top 72 can be a single piece (i.e., a lid) that is removed while the container is being filled, or divided into two portions (such as a box top) so that the halves of top 72 can be pulled away from the top opening of container 60.

Container 60 can be a large box, or any container that is able to hold a large quantity of a product or material. Container 60 can be made of any material, including, but not limited to, cardboard, wood, metal, paper, plastic, composite, or polymer. Container 60 preferably has dimensions of about forty inches (40″) by about forty-eight inches (48″) by about forty-six inches (46″), in order to fit easily on a pallet. However, container 60 can be of any dimension that permits indexed rows or layers of continuous web 20 to be packaged therein by the present method.

FIGS. 37A and 37B illustrate yet another embodiment in which continuous web 120 is dispensed into container 160 as a plurality of rows 122 that are each indexed (offset) from the previous row by a certain distance. The plurality of rows form a first horizontal layer, second horizontal layer, and so on until container 160 is filled to a desired height, weight, or quantity of continuous web 120. In FIG. 37A, container 160 is positioned on pallet 97.

Indexed rows are formed by dispensing a first row 124 of continuous web 120 into container 160 by festooning device 180, starting at a first edge 163 in container 160. Alternatively, first row 124 can start at any position on the bottom of container 160. After first row 124 is dispensed into container 160 and reaches an opposite edge 165 (opposite in relation to starting edge 163), festooning device 180 reverses direction, thereby folding over continuous web 120 to produce a fold 125. Festooning device 180 then dispenses a second row 126 of continuous web 120 into container 160 that partially overlaps first row 124 but is indexed (shifted) in relation to first row 124 by a certain distance that is called an index distance 130, as illustrated in FIG. 37B, and in FIGS. 38A and 38B.

When second row 126 is dispensed by festooning device 80 and reaches edge of container 60, festooning device 180 reverses direction again, forming a fan fold of continuous web 120, and starting a third row 128 of continuous web 20 that partially overlaps second row 126 but is indexed (shifted) by index distance 130 relative to second row 126 away from first row 124. This is also illustrated in FIGS. 38B and 38C. In this way, continuous web 120 is fan folded in container 160.

Further steps may be taken to increase the amount of continuous web 20 that can be dispensed into container 60. To help anchor first row 124 to container 60, a portion of first row 124 can be fastened or adhered to container 60 with a fastener such as, but not limited to, glue, tape, and hook-and-eye devices such as VELCRO®.

A mechanical device, such as a “fork” (not shown) can be inserted into fold 125 to press and force fold 125 as close as possible to edge 165 of container 160, in order to provide a maximum “footprint” of continuous web 120 in container 160. Alternatively, a device that provides a burst of compressed air can be used to accomplish this. For instance, with reference to FIG. 37B, a fork or similar device could be inserted between first row 124 and second row 126 to press fold 125 toward edge 165. Pressing a fold toward an edge is particularly useful when continuous web 120 is thick or stiff and the row would otherwise end some distance short of edge 165.

In another embodiment, a delay can be programmed so that festooning device 180 makes several extra passes to dispense additional amounts of continuous web 120 at the edge of container 160, to make the fill more level and stable.

The usual back-and-forth dispensing of continuous web 120 can cause “crowning” of the product in container 160. “Crowning” means forming a higher mound of material in the center portion of the container as compared with the edges. Crowning tends to occur when the continuous web is a higher-ply, thicker material. Crowning creates wasted space in the container, and can make the container unstable and unbalanced.

To reduce or eliminate crowning, an embodiment of the present method includes providing one or more extra passes of the festooning device to dispense extra material at the edge of the container before reversing direction. This can be achieved by programming the PLC Controller to provide extra passes at each edge. Generally, when the container reaches the end of the conveyor (not shown), the festooning device changes directions. However, there can be a slight delay programmed in the PLC Controller that causes the festooning device to make extra passes that lay down extra material at the edges of the container. Preferably, the PLC Controller is programmed for two (2) to four (4) extra passes at each edge. The extra material laid down at the container edges creates a more “level fill” of the container as compared with conventional packaging techniques. By contrast, an “unlevel-fill” container empties unevenly, and the remaining rows of material may tip over. By providing extra material at the edge for a level fill from bottom to top of the container, the container produced by the present method empties evenly and securely for an end-user or customer.

In one embodiment, the above process can be automated by using a level sensor (not shown) to sense whether or not the container has a level fill, and programming one or more extra passes at the edges of the container based on that input before reversing direction. In another embodiment, conveyor speed (on which the container is resting) can be changed to increase or decrease the number of extra passes at the edge of the container. Changes in conveyor speed and/or extra passes of the festooning device can be used to generate a level fill of the container. In yet another embodiment, the operator can manually temporarily block the sensor beam to cause the festooning device to lay down one or more extra layers at the edge of the container.

As noted above and illustrated in FIG. 37B, first row 124 and second row 126 are offset or displaced in relation to each other by index distance 130. In the particular exemplary embodiment in FIG. 37B, index distance 130 is shown as ¼″. However, index distance 130 can be any amount or distance that is less than an extent (usually width) of continuous web 120, as long as there is a partial overlap between two adjacent rows. Index distance 130 depends on the dimensions and characteristics of continuous web 120 being dispensed into container 160. Typically, index distance 130 can be from about five-hundredths of an inch (0.05″) to about ten inches (10″). Index distance 130 is preferably from about one-tenth of an inch (0.10″) to about five inches (5″), and more preferably from about one-fifth of an inch (0.20″) to about two inches (2″). Index distance 130 can be identical between successive adjacent rows (e.g., index distance 130 between first row 124 and second row 126 would be identical to index distance 130 between second row 126 and third row 128), or can have an index distance 130 that varies among successive rows. Index distance 130, when not a uniform amount, can vary according to a fixed ratio among rows or can vary randomly. For example, index distance 130 can be made to vary among successive rows according to a certain ratio (e.g., a ratio of 1:3, where index distance 130 is ¼″ between first row 124 and second row 126, and is ¾″ between second row 126 and third row 128, and is ¼″ between third row 128 and a fourth row (not shown), and so on). The physical characteristics of continuous web 120, such as its thickness, stiffness, coefficient of friction, can affect the choice of index distance 130 between rows.

The offset of adjacent rows, such as between first row 124 and second row 126, is created by a movement by festooning device 180, or by a movement of container 160, and/or by a combination of both, that displaces the row of continuous web 120 being dispensed into container 160 by a specified amount from the previous row. As illustrated in FIG. 37A and FIG. 37B, second row 126 is dispensed into container 160 so as to partially overlap first row 124 (in an opposite or reciprocal direction in this exemplary embodiment), but is offset from first row 124 by index distance 130. Such movement of festooning device 180 and/or container 160 is repeated for a plurality of rows 122 of continuous web 120, with each new row placed in an opposite direction to form a fan fold, and is indexed in relation to the previous row. Such indexed rows form a first horizontal layer of continuous web 20 that extends from end 167 to its opposite end 169 of container 160. After completion of a first horizontal layer, the process is repeated toward the opposite direction to form a second horizontal layer that extends from end 169 back to opposite end 167. This continues until container 160 is filled with horizontal layers of continuous web 120 up to a desired height, weight, or quantity. This method can be used to dispense a single, continuous length of continuous web 120 into container 160; or, alternatively, to dispense more than one length of continuous web 120 in container 160.

FIGS. 38A through 38C illustrate an exemplary embodiment of the present method to placing successive rows of continuous web 120 in container 160. FIG. 38A illustrates laying a first row 124 of continuous web 120 along the bottom of container 160, starting at the edge marked A1 and dispensing the first row 124 to reach edge A2.

FIG. 38B shows that, after first row 124 of continuous web 120 reaches edge A2, the festooning device reverses direction and dispenses a second row 126 of the same continuous web 120 in container 160 in an opposite (or reciprocal) direction from first row 124, that is, from the edge marked A2′ to edge A1′. However, as shown in FIG. 38B, second row 126 does not completely overlap first row 124, but rather overlaps only a part of first row 124. The amount that second row 126 is offset from first row 124 is index distance 130.

Referring to FIG. 38C, the method continues as a third row 128 of the same continuous web 120 is placed in container 160 in an opposite (or reciprocal) direction on second row 126, i.e., from the edge marked A1″ to edge A2″, but third row 128 is displaced or offset from second row 126 by an index distance 130, such that third row 128 partly, but not completely, overlaps second row 126.

The process shown in FIG. 38A through FIG. 38C illustrate a pattern by which three rows of continuous web 120 are placed into container 160 by an embodiment of the present method. The method continues in this same way, along the direction indicated by the large arrow underneath each of FIGS. 38A-38C, with successive rows (fourth row, fifth row, and higher, not shown) being placed in container 160 such that the entire bottom of the container is covered with continuous web 120, from first end A1/A2 to opposite (second) end B1/B2. The fan folded, indexed rows thereby form a first horizontal layer across an extent of the container. In the exemplary embodiment illustrated in FIGS. 38A to 38C, the first row 124, second row 126, and third row 128, each of which is indexed by index distance 130 in relation to the next-previous row, together comprise a portion of one horizontal layer in container 160.

When each horizontal row of continuous web 120 is placed in container 160—for instance, when a row is laid between along end B1/B2 in FIG. 38C—the method proceeds in the same manner as before but in the opposite direction, placing successive rows of continuous web 20 from end B1/B2 toward end A1/A2, each row of which is offset or displaced from the next-earlier row by an index distance 130. In this way, a second horizontal layer of continuous web 120 is placed over the first horizontal layer in container 160.

Once the second horizontal row is completed (i.e., when the row of continuous web 120 reaches end A1/A2), the method begins a third horizontal row in the opposite direction, laying down rows of continuous web 120 from A1/A2 to B1/B2, to form a third horizontal layer that rests on the second horizontal layer and first horizontal layer. A plurality of horizontal layers is laid in container 160 until filled to a desired height, weight, or number of units of continuous web 120.

Although FIGS. 38A to 38C show an exemplary embodiment of rows laid in patterns of first row from A1 to A2, then a second row from A2′ to A1′ and a third row A1″ to A2″, a variety of other patterns to lay down the rows of continuous web 120 can also be used. Using the same identifiers as used in FIGS. 38A to 38C, the continuous web 120 can be laid down in a pattern that starts around the perimeter of container 160 (A1 to A2, A2 to B2, B2 to B1, B1 to A1—in a “box” pattern), and then adds a second layer of continuous web 20 that is indexed (offset) a desired distance from the first layer, following the same pattern. Other patterns, such as cross-hatching (A1/A2 to B1/B2, followed by zig-zag patterns A1 to B2, B2 to A2, A2 to B1, B1 to A1) are also possible in the present method, depending on the shape, thickness, and stiffness of continuous web 120, as long as successive rows are indexed (offset) a certain distance from the previous row to provide a partial overlap.

Continuous web 120 can be a single continuous strip among first row 124, second row 126, third row 128, and all subsequent rows, until container 160 is filled, thereby producing a container 160 that is packaged with a continuous length or strip of continuous web 120 that is fan folded, and has indexed layers. Alternatively, a cut or break in continuous web 120 can be made by the manufacturer when a desired length of material is reached; for example, after a certain number of linear feet have been packaged. In this way, two or more lengths of a strip of continuous web 120 can be placed in container 160.

Although continuous web 120 is continuous, there can be perforations or cut-lines made on continuous web 120 to assist the end-user to identify individual products in the continuous web. For example, continuous web 120 may be a long strip of absorbent food pads, with perforations between individual absorbent food pads.

The preceding disclosure refers to a single pass of a continuous material as a “row,” but the same could also be referred to as a “layer.” Thus, the present method comprises a method of packaging a container 160 using a series of passes of festooning device 180 to place indexed layers of continuous web 120 that are each offset or shifted in relation to an underlying layer by a certain index distance 130, so that the individual layers partially overlap to form indexed layers. A series (or set) of such indexed layers across a level of container 160 forms a horizontal layer. Horizontal layers are formed in this manner to fill container 160 with a desired amount of continuous web 120.

As used herein, an “end-user” is a customer or employee who removes and uses continuous web 120 that has been previously packaged in container 160 for its intended use.

The present method can be used for packaging and dispensing a continuous web of a variety of products or materials, including those that are fibrous materials, such as fabrics and non-wovens. The present method for packaging can also be used for packaging and/or dispensing finished products, including products that can be dispensed as a continuous piece and cut by the end-user, for example, absorbent food pads and/or other absorbent articles. The product or materials that are packaged by the present method are typically uniform in thickness, size, and/or texture, but the present method also can be used for packaging a continuous length of a product having varied parameters at various locations along in its continuous length, as long as the successive rows could be laid into container 160.

As an example, a continuous length of absorbent food pads of more than 21,000 linear feet can be packaged in container 160 by the present method as a single, continuous length, with marks or perforations to indicate the individual food pads. To remove the absorbent food pads from container 160 that were placed therein using the present method, an end-user is able to set up the packaged container one time to permit all of the absorbent food pads to be dispensed continuously and quickly from container 160. The absorbent food pads, in this example, can be cut (or separated along pre-made perforations) to a desired size to fit in a food tray as they are dispensed.

The present method offers several other advantages over packaging the same product by winding on a large-diameter roll. A roll does not hold as many linear feet of a product as can be packaged in container 160 by the present method. Also, a roll is more difficult for an end-user to load, as a roll must be lifted onto a spindle before the product could be dispensed. Also, a large roll requires more space for shipping, with more wasted space between rolls, as compared with container 160. Also, container 160 fits on pallet 97, and so can be more easily transported than the same material packaged on a roll.

The present method also offers several other advantages over conventional packaging techniques that places long strips of products or material in a container. Conventional packaging techniques lay successive rows of product or material to form a series of stacks or “lanes” in the container, which can cause the container to become unstable during the dispensing process as the stacks are depleted, and risks having the remaining stacks fall over into the interior of the container that is vacated during the dispensing process. By comparison, the horizontal layers formed by the present method can be dispensed by an end-user without causing instability of the container 160, as continuous web 120 is dispensed evenly from the length and width of the entire container. Also, conventional packaging techniques do not permit an entire container to be dispensed as a single, continuous feed unless the adjacent lanes are spliced together. By contrast, the present method permits all of continuous web 120 to be dispensed from container 160 as a single, continuous length (if desired), without splicing.

The present method also avoids the need to place dividers between the vertical stacks or lanes that are formed by conventional packaging techniques. By comparison, the horizontal layers formed by the present method offer the advantages of stability when removing continuous web 120 from container 160, eliminate the need to use dividers, and maximize the use of space within container 60, thereby providing an end-user with greater safety and speed.

Each container that is packaged or filled by the present method can have a “tail” of product or material 120. The tail can extend outside of container 160 or can be contained inside of it. If desired, a tail from a first container can be connected to a tail in a second container, to further increase the efficiency of the method to dispense a continuous feed from the first and second containers with a single set-up.

Packaging the continuous web in a container by the present method has advantages as compared to conventional methods that wind the web around a central tube to form a large-diameter product roll. The present method allows a greater amount of the continuous web to be packaged in a container as compared with rolling up the continuous web onto a large roll. Also, the container packaged using the present method is able to rest solidly and securely on a pallet, and so is safer and easier to transport than a continuous web wound onto a large roll. Also, a container packaged by the present method can be placed on a floor or table for unloading as a continuous feed by an end-user, which avoids the need to lift and load a large roll onto a spindle.

As used in this application, the word “about” for dimensions, weights, and other measures means a range that is ±10% of the stated value, more preferably ±5% of the stated value, and most preferably ±1% of the stated value, including all subranges therebetween.

It should be understood that the foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications, and variances that fall within the scope of the disclosure. 

What is claimed is:
 1. A festooning device for packaging a continuous length of a material or a product in a container, comprising: a frame assembly; a dispensing shuttle; and a drive motor; wherein the festooning device can package the continuous length of the material or the product into the container at high operating speeds.
 2. The festooning device according to claim 1, further comprising: a linear actuator.
 3. The festooning device according to claim 1, further comprising: an articulating arm nipped roll drive assembly.
 4. The festooning device according to claim 1, further comprising: an articulated paddle.
 5. The festooning device according to claim 4, further comprising: a controller that regulates the motion of the articulated paddle.
 6. The festooning device according to claim 1, wherein the container is filled with a continuous length of the material or the product formed into one or more horizontal, indexed layers.
 7. The festooning device according to claim 1, further comprising: a sensor that detects the level of the material or the product in the container.
 8. The festooning device according to claim 7, wherein the sensor provides a value used to adjust a travel distance of the dispensing shuttle.
 9. The festooning device according to claim 7, wherein the sensor provides a value used to adjust an oscillation of an articulated paddle.
 10. The festooning device according to claim 8, wherein the adjustment to the travel distance of the dispensing shuttle avoids overthrowing the material or product outside of the container.
 11. The festooning device according to claim 9, wherein the adjustment to the oscillation of the articulated paddle avoids overthrowing the material or product outside of the container.
 12. The festooning device according to claim 4, wherein a motion of the dispensing shuttle and a motion of the articulated paddle are synchronized with a motion of the container, whereby the synchronized movements produce more-complete, more-level filling of the container with the material or the product at high operating speeds.
 13. The festooning device according to claim 1, wherein the material or the product has a varied thickness and/or stiffness that can be dispensed into the container by the festooning device without operator adjustments.
 14. A system for packaging a continuous length of a material or a product in a container comprising: a feeder roll of the material or the product; a dancer assembly that receives the material or product dispensed from the feeder roll, wherein the dancer assembly comprises a fixed arm connected to two rollers at opposite ends, a dancer pulley, and a dancer position sensor, and wherein the dancer assembly has a pivot point around which the fixed arm pivots; a motor that drives the feeder roll; a controller that is connected to the motor and regulates the speed of the feeder roll; a festooning device for dispensing the material or the product into the container; and a container that receives the material or the product dispensed by the festooning device.
 15. The system according to claim 14, wherein the controller measures a speed differential between an incoming speed and an outgoing speed to generate a signal that is sent to the motor to regulate motor speed.
 16. The system according to claim 14, wherein the dancer assembly allows the system to automatically adjust for a continuous length of material having a variable thickness and/or a variable stiffness.
 17. A method of using a festooning device for packaging a continuous length of a product in a container, comprising: dispensing the product into the container with the festooning device to form a first row across a lengthwise direction; indexing the product by a first index distance that is shifted in relation to the first row; dispensing a second row of the product in the container with the festooning device to form a partial overlap of the second row along a lengthwise dimension of the first row, wherein the second row is offset in relation to the first row by the first index distance; dispensing one or more additional rows of the product into the container, wherein each of the one or more additional rows is offset from an immediate previous row by a second index distance, wherein the first row, the second row, and the one or more additional rows of the product form a horizontal layer of the product in the container.
 18. The method according to claim 17, wherein the container is filled with a continuous length of the product formed into horizontal, indexed layers.
 19. The method according to claim 17, wherein the indexing is performed by shifting the festooning device in relation to the container, shifting the container in relation to the festooning device, or shifting both the festooning device and the container, wherein each row is offset from an earlier row by an amount of the index distance.
 20. The method according to claim 17, further comprising: reversing direction of dispensing after the horizontal layer of indexed rows of the product reaches a widthwise edge of the container; and repeating the dispensing and the indexing to form a second horizontal layer of indexed rows of the product in the container. 